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Intelligente

Energy recovery systems

INTELLIGENTE
Energy recovery systems

Poppi Clementino Spa specialises in optimising energy consumptions. By accurately analysing the energy consumptions of production processes the company is thus able to offer its customers tailored energy recovery and pollutant abating solutions.
When producing ceramic claddings and flooring, the two machines used for this process that require the most energy are, in order, Atomizers and Driers (and Kilns).
Poppi Clementino Spa has developed a combined system which focuses on recovering energy from ceramic kilns: this is the main source of recovery and concerns the cooling air used at the end part of the kilns normally dispersed through stacks. Even the fume stacks themselves contain a lot of energy that is usually dispersed but which can be recovered.
Normally energy recovery of cooling air is called “Direct Recovery”. On the contrary, the recovery of the potential energy of fumes – normally achieved by using a heat exchanger – is called “Indirect Recovery". In the majority of cases both the “direct” and “indirect” systems are combined to reach maximum efficiency.

Direct Recovery system:

The example described below refers to a combined system where the hot air coming from the kiln cooling stacks is recycled to the atomizers’ combustion chambers at a temperature of 170°C. In this case, an inverter is used to control fan speed, sized specifically; the system described can reach savings of up to 20-25% on the annual energy consumptions required to operate the atomizers.

Indirect Recovery system:

The heat contained in the fumes, normally dispersed through stacks, requires adequate treatment due to the content of corrosive agents – these are the combustion residues in a ceramic kiln. An air/fumes heat exchanger is normally used for this treatment in order to have a flow of hot, clean air that can be reutilized. The flow of hot air is sent through adequately insulated pipes to minimize the loss of heat which adds up to only 1°C every 10-15 metres of pipe. By adequately implementing this system it is normally possible to save in the region of 25-30% of the driers’ total energy consumption.